MeasurementPub Date : 2025-09-29DOI: 10.1016/j.measurement.2025.119166
Minwoo Kang , Kiyoon Yi , Hoon Sohn
{"title":"Laser ultrasonic inspection of wire welds in cylindrical lithium-ion battery pack","authors":"Minwoo Kang , Kiyoon Yi , Hoon Sohn","doi":"10.1016/j.measurement.2025.119166","DOIUrl":"10.1016/j.measurement.2025.119166","url":null,"abstract":"<div><div>As the demand for lithium-ion batteries continues to increase, quality control and safety assurance become increasingly critical in the battery manufacturing industry. This study presents a laser ultrasonic inspection technique to evaluate the quality of the welding between a wire and a busbar in a cylindrical lithium-ion battery pack. Ultrasonic waves are generated using a neodymium-doped yttrium aluminum garnet (Nd:YAG) laser at the wire, and the corresponding ultrasonic responses are measured at both the wire and busbar using a laser Doppler vibrometer (LDV). The proposed technique is based on the principle that inadequate welding leads to poor transmission of ultrasonic waves from the wire to the busbar. Based on this concept, an ultrasonic energy ratio is defined as the ratio of the ultrasonic wave energy measured at the wire to that measured at the busbar. Numerical simulations and experimental tests demonstrate a strong correlation (correlation coefficient R<sup>2</sup> = 0.8899) between the welding condition and the energy ratio. The proposed laser ultrasonic inspection technique enables non-contact and non-destructive evaluation of welds, offering potential for in-situ and in-line inspection of cylindrical lithium-ion-battery packs.</div></div>","PeriodicalId":18349,"journal":{"name":"Measurement","volume":"258 ","pages":"Article 119166"},"PeriodicalIF":5.6,"publicationDate":"2025-09-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145269677","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
MeasurementPub Date : 2025-09-28DOI: 10.1016/j.measurement.2025.119173
Jia Zhang , Hairong Zhu , Lei Wang , Zhongjie Li , Tong Sun , Shengli Wang
{"title":"An improved variational Bayesian adaptive robust filtering algorithm for LBL/SINS integrated navigation in complex marine environments","authors":"Jia Zhang , Hairong Zhu , Lei Wang , Zhongjie Li , Tong Sun , Shengli Wang","doi":"10.1016/j.measurement.2025.119173","DOIUrl":"10.1016/j.measurement.2025.119173","url":null,"abstract":"<div><div>In the context of LBL/SINS integrated navigation systems, the Kalman Filter (KF) often encounters difficulties in handling dynamic noise, signal loss, and measurement outliers. To address these challenges, this paper introduces an improved Variational Bayesian Adaptive Robust Filter (VBARKF), which estimates both process and measurement noise statistics. To mitigate the impact of beacon signal loss, the proposed method employs an adaptive beacon validity vector that dynamically adjusts the dimensionality of the measurement equation. Furthermore, to counteract the influence of gross errors, the VBARKF integrates a robust filtering mechanism based on the Mahalanobis distance. Specifically, the Mahalanobis distance between the slant distance derived from LBL and SINS is compared with a predefined threshold, enabling the dynamic adjustment of measurement weights. Experimental results from an offshore field trial demonstrate that the VBARKF improves positioning accuracy by 83.03% compared to the KF. It also outperforms Unscented Kalman Filter (UKF), VBAKF-R, VBARKF-R, robust Student’s t based Kalman filter (RSTKF) and VBAKF by 73.59%, 67.19%, 60.35%, 38.31% and 6.55%, respectively. In addition, underwater semi-physical experiments show an improvement in accuracy using VBARKF, surpassing KF, UKF, VBAKF-R, VBARKF-R, RSTKF, and VBAKF by 49.13%, 45.81%, 44.26%, 42.08%, 36.38%, and 30.11%, respectively. These findings underscore the robustness and reliability of the VBARKF, making it a promising solution for precise underwater navigation in applications such as underwater remote sensing, ocean mapping, and underwater rescue.</div></div>","PeriodicalId":18349,"journal":{"name":"Measurement","volume":"258 ","pages":"Article 119173"},"PeriodicalIF":5.6,"publicationDate":"2025-09-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145221649","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Highly sensitive temperature sensor based on tunable stoichiometric alternative plasmonic material using multiple thermo-responsive analytes","authors":"Md. Shakibur Rahman , Rizwanur Rahad , Dil Mahfuzur Rahman , Md. Jahidul Hoq Emon , Rummanur Rahad","doi":"10.1016/j.measurement.2025.119127","DOIUrl":"10.1016/j.measurement.2025.119127","url":null,"abstract":"<div><div>This study presents a CMOS-compatible plasmonic sensor designed for temperature detection across multiple thermo-responsive analytes with ultra-high sensitivity. Addressing the limitations of traditional plasmonic materials, we explore yttrium-doped titanium nitride (TiN) as an alternative, offering enhanced stability, thermal durability, and compatibility with CMOS fabrication processes. The sensor, featuring a double-ring connected resonator, achieves a refractive index sensitivity of 3863.54 nm/RIU and a temperature sensitivity of 2.44735 nm/°C in a chloroform-based medium. By optimizing yttrium doping levels, we balance plasmonic tunability with material stability, as evidenced by dielectric permittivity and SPPs parameters and found that the ratio of Ti and Y having 91%:9% exhibits higher sensitivity than the others (63%:37%, 79%:21%, 85%:15%). Comparative analysis across dielectric environments highlights the sensor’s adaptability and high sensitivity in different thermo-responsive dielectric media. Thus, this work advances plasmonic sensor technology for precise temperature sensing applications.</div></div>","PeriodicalId":18349,"journal":{"name":"Measurement","volume":"258 ","pages":"Article 119127"},"PeriodicalIF":5.6,"publicationDate":"2025-09-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145269149","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
MeasurementPub Date : 2025-09-28DOI: 10.1016/j.measurement.2025.119159
Qiang Zhang , Lei Chang , Mohammed El-Meligy , Khalid A. Alnowibet
{"title":"On the measurement of nonlinear aeroacoustics characteristics of solar cell structures using a novel metrological framework validated by a machine learning algorithm","authors":"Qiang Zhang , Lei Chang , Mohammed El-Meligy , Khalid A. Alnowibet","doi":"10.1016/j.measurement.2025.119159","DOIUrl":"10.1016/j.measurement.2025.119159","url":null,"abstract":"<div><div>This study created a new metrological framework for the modeling of nonlinear phase velocity, propagation, and aeroacoustic evaluation of multilayer silicon solar cell structures with graphene platelet (GPL)-metal layers. The solar cells were evaluated under the combined external sound radiation effects and airflow pressure subjected to coupled vibrational acoustic responses. A corrected structural modeling method using higher-order shear deformation theory (HSDT), where transverse shear stresses continuously vary through the thickness, and modified couple stress theory (MCST) to account for size-dependent phenomena at the microscale. The governing partial differential equations using the variational energy method were constructed, and an analytical harmonic-based approach is used to solve the governing equations. The Newmark’s transition is used to compute dynamic vibration response in order to accurately define transient outcomes. To ensure both reliability and predictive ability, the framework is validated with a hybrid deep neural network model (HDNNM) that uses machine learning to relate input parameters—GPL weight fraction, frequency stemmed from the excitation, and airflow velocity—to general nonlinear response performance metrics of sound pressure level and phase velocity changes. The contribution of the proposed mechanics-based modeling with machine learning represents a reliable method to evaluate metrics measured from metrology specific to solar cell structures subjected to aerodynamic acoustic conditions generally within the environmental regime. The findings further document the contributions of GPLs as strengthening or reinforcement of a structure’s stiffness and damping characteristics, which similarly enhances a structure’s energy conversion stability and acoustic properties. Lastly, these divergent thinking methodologies and experimental evidence will promote new insights into structural health monitoring, noise mitigation, and the evaluation of the next generation of solar energy devices.</div></div>","PeriodicalId":18349,"journal":{"name":"Measurement","volume":"258 ","pages":"Article 119159"},"PeriodicalIF":5.6,"publicationDate":"2025-09-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145269153","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
MeasurementPub Date : 2025-09-28DOI: 10.1016/j.measurement.2025.119161
Mina Ghanbari , Saber Azizi , Ghader Rezazadeh
{"title":"Measurement and nonlinear analysis of an inertial sensor with micropillar gap filler under voltage modulation","authors":"Mina Ghanbari , Saber Azizi , Ghader Rezazadeh","doi":"10.1016/j.measurement.2025.119161","DOIUrl":"10.1016/j.measurement.2025.119161","url":null,"abstract":"<div><div>Inertial sensors, particularly capacitive MEMS accelerometers, are indispensable for accurately measuring acceleration and orientation. This study examines the dynamic behavior of a plate positioned on a polymeric micropillar array, such as PDMS, subjected to base excitation through harmonic acceleration and a direct current (DC) bias voltage. The PDMS micropillars are represented through finite deformation theory using a Neo-Hookean approach to account for their quadratic, cubic, and coupled nonlinearities. Governing equations have been formulated to describe the vertical compression and rotational modes of the plate, placing special emphasis on the compression mode resulting from the uniform distribution of both the gap and the mass. The findings from the static analysis reveal that saddle-node bifurcation occurs at a critical voltage. Notably, the pull-in voltage identified is substantially lower than that seen in traditional capacitive systems. These characteristics indicate that the design is particularly well-suited for low-voltage applications, highlighting its potential to operate efficiently in such environments. This makes the design suitable for low-voltage applications. The system demonstrates stability for deflections up to 44% of the gap, a notable improvement over the 33% limit observed in conventional designs, thereby extending the operational range. A rise in the dielectric permittivity of the micro pillars, achieved for instance through the incorporation of nanoparticles, results in a reduction of the pull-in voltage while simultaneously enhancing the variation in capacitance. This modification not only reduces the voltage required for operation but also enhances the system’s sensitivity by allowing for more significant capacitance changes. The dynamic analysis reveals a plethora of nonlinear behaviors, including wideband frequency responses, significant 2<em>x</em> harmonic generation, and bifurcations such as period doubling at specific frequencies. The broad frequency response enhances the suitability of the structure for wideband energy harvesting, whereas the bifurcation behaviors offer potential for sensitive switching. These findings provide important insights into the nonlinear interactions in micro-pillar-supported capacitive systems, paving the way for advancements in energy harvesting, actuation, and precision sensing applications.</div></div>","PeriodicalId":18349,"journal":{"name":"Measurement","volume":"258 ","pages":"Article 119161"},"PeriodicalIF":5.6,"publicationDate":"2025-09-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145222267","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
MeasurementPub Date : 2025-09-28DOI: 10.1016/j.measurement.2025.119170
Priyom Goswami, Rajiv Nandan Rai
{"title":"Water ingressed lubrication oil degradation with cavitation effect detection in gearbox using sound pressure level analysis","authors":"Priyom Goswami, Rajiv Nandan Rai","doi":"10.1016/j.measurement.2025.119170","DOIUrl":"10.1016/j.measurement.2025.119170","url":null,"abstract":"<div><div>This study introduces a novel methodology for diagnosing water ingress-induced lubrication oil degradation and cavitation effects in industrial gearboxes using Sound Pressure Level (SPL) analysis, offering a real-time, non-invasive alternative to conventional vibration-based or spectroscopic techniques. Experimental investigations reveal a strong correlation between elevated SPL values and water contamination in lubrication oil, enabling early detection of gearbox failures while emphasizing the importance of maintaining optimal oil levels to minimize mechanical losses, enhance efficiency, and extend operational lifespan. To address the complexities of fault diagnosis under interaction effects between gear faults and oil types, a machine learning-based classification framework was developed using SPL features, achieving 96.3% accuracy in detecting lubrication degradation and in classifying combined faults. These findings validate SPL as a cost-effective and scalable diagnostic tool that complements existing condition monitoring techniques, offering a comprehensive approach to gearbox health assessment. By integrating SPL analysis with other methods, this research paves the way for intelligent maintenance strategies that enhance gearbox reliability, reduce downtime, and deliver significant cost savings in industrial applications.</div></div>","PeriodicalId":18349,"journal":{"name":"Measurement","volume":"258 ","pages":"Article 119170"},"PeriodicalIF":5.6,"publicationDate":"2025-09-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145222800","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
MeasurementPub Date : 2025-09-28DOI: 10.1016/j.measurement.2025.119169
Christian A. Salcedo-Rodriguez , Eloisa Gallegos-Arellano , Juan C. Hernandez-Garcia , Daniel A. Ramos-Gonzalez , Marco I. Estrada-Pintor , Maria S. Avila-Garcia , Paulo A. Delgado-Arredondo , Juan M. Sierra-Hernandez
{"title":"Molecular spectroscopy analysis of SF6 absorption bands for the design of highly sensitive NDIR sensors for industrial applications","authors":"Christian A. Salcedo-Rodriguez , Eloisa Gallegos-Arellano , Juan C. Hernandez-Garcia , Daniel A. Ramos-Gonzalez , Marco I. Estrada-Pintor , Maria S. Avila-Garcia , Paulo A. Delgado-Arredondo , Juan M. Sierra-Hernandez","doi":"10.1016/j.measurement.2025.119169","DOIUrl":"10.1016/j.measurement.2025.119169","url":null,"abstract":"<div><div>Sulfur hexafluoride (SF<sub>6</sub>) is a widely used gas in the industry in high- and medium-voltage equipment that, in the long-term, can suffer from gas leaks. SF<sub>6</sub> leak detection with optical means has been reported previously using the primary absorption band <span><math><mrow><msub><mi>v</mi><mn>3</mn></msub></mrow></math></span> for gas concentration below 0.1 %. This work aims to use molecular spectroscopy to examine the SF<sub>6</sub> absorption bands as an alternative approach to develop non-dispersive infrared (NDIR) sensors capable not only of monitoring real-time gas changes in gas-insulated substations (GIS), but also of improving sensitivity and detection percentages above 0.1 %. An experimental setup is proposed using a Fourier Transform Infrared Spectrophotometer (FTIR) to analyze the SF<sub>6</sub> concentration changes. Results show that the <span><math><mrow><msub><mi>v</mi><mn>3</mn></msub></mrow></math></span> primary absorption band exhibits a pronounced sensitivity to concentrations below 0.2 %, whereas at elevated levels, it exhibits a diminished sensitivity, and at concentrations above 10 %, it demonstrates low sensitivity. In contrast, the combination bands do not demonstrate sensitivity for concentrations below 0.2 % but exhibit an increase in sensitivity above that concentration. A basic SF<sub>6</sub> NDIR sensor was implemented to validate the results obtained. The implemented sensor has a detection limit of 25 ppm, and it was demonstrated that it is possible to enhance the sensitivity of NDIR sensors that solely consider the <span><math><mrow><msub><mi>v</mi><mn>3</mn></msub></mrow></math></span> band by employing the combination bands for detection in gas concentrations above 0.2 %. This work serves as a basis for enhancing the design of NDIR sensors by modifying their configuration to optimize accuracy and robustness.</div></div>","PeriodicalId":18349,"journal":{"name":"Measurement","volume":"258 ","pages":"Article 119169"},"PeriodicalIF":5.6,"publicationDate":"2025-09-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145221668","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
MeasurementPub Date : 2025-09-28DOI: 10.1016/j.measurement.2025.119174
Wen Nie , Junchao Wan , Huitian Peng , Huaitong Li
{"title":"Mechanism of the influence of relative humidity on coal mine dust light scattering and the correction of mass concentration inversion","authors":"Wen Nie , Junchao Wan , Huitian Peng , Huaitong Li","doi":"10.1016/j.measurement.2025.119174","DOIUrl":"10.1016/j.measurement.2025.119174","url":null,"abstract":"<div><div>The relative humidity in underground mines fluctuates due to various factors, including geological conditions, ventilation, temperature, and dust suppression. As humidity increases, dust particles undergo hygroscopic expansion and aggregation, leading to changes in particle size and refractive index. Here, we established a humid aerosol light scattering measurement platform and introduced a relative humidity deviation factor to quantify the deviation in scattered light intensity per unit mass concentration of coal dust and rock dust under different humidity conditions. Under high-humidity conditions, the scattering intensity of coal dust decreases by about 30 %. In contrast, Rock dust, however, exhibits an ∼8.7 % increase due to hygroscopic growth, yet the overall relative humidity deviation factor remains approximately 0.789. Given this divergence, we revealed the mechanism by which the coupling of relative humidity and chemical composition affects the light scattering behavior of mine dust. Exponential fitting (with R<sup>2</sup> = 0.981 and R<sup>2</sup> = 0.965) and polynomial fitting (with R<sup>2</sup> = 0.995 and R<sup>2</sup> = 0.993) were performed for the correction coefficients of scattered light intensity and the particle size growth functions of coal dust and rock dust under different humidity conditions. The experimental results indicate that by constructing a dynamic humidity correction model to adjust the inversion of dust mass concentration, the relative measurement error of the sensor for dust mass concentration under conditions of medium or high humidity can be reduced to less than 10 %. This represents a novel approach for the accurate detection of dust in mines.</div></div>","PeriodicalId":18349,"journal":{"name":"Measurement","volume":"258 ","pages":"Article 119174"},"PeriodicalIF":5.6,"publicationDate":"2025-09-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145222801","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
MeasurementPub Date : 2025-09-28DOI: 10.1016/j.measurement.2025.119175
Yan Wang , Geng Tong , Ben Li , Wenli Li , Jiancun Zhao , Honglong Chang , Yiting Yu
{"title":"Fabrication-friendly filtering channel optimization strategy for hyperspectral reconstruction","authors":"Yan Wang , Geng Tong , Ben Li , Wenli Li , Jiancun Zhao , Honglong Chang , Yiting Yu","doi":"10.1016/j.measurement.2025.119175","DOIUrl":"10.1016/j.measurement.2025.119175","url":null,"abstract":"<div><div>Hyperspectral image recovery has attracted much attention due to its cost-effectiveness. Existing approaches mainly focus on enhancing reconstruction accuracy, either by optimizing network architectures from single RGB image or by optimizing customized filtering channels. However, reconstruction from an RGB image is limited due to their inherent channels. More critically, current methods for optimizing customized channels always neglect critical fabrication feasibility. Here, we propose a fabrication-friendly filtering channel optimization strategy for hyperspectral reconstruction. To the best of our knowledge, it is the first strategy which achieves the balance between high reconstruction accuracy and fabrication feasibility. This is realized by primarily combining the target feature matching and channel correlation-based optimization method with the film design optimization method accounting for manufacturing errors. Our proposed strategy has been validated using both synthetic datasets and real-world scenarios. Experimental results on synthetic datasets demonstrate the proposed method outperforms existing channel optimization methods in both reconstruction accuracy and fabrication friendliness. In real-world testing, our method improves reconstruction accuracy compared to conventional RGB channels. Specifically, it achieves a peak signal-to-noise ratio improvement of over 18.2% while reducing the root mean square error by at least 45.6%, the mean relative absolute error by no less than 50.2 %, and the spectral angle mapper by a minimum of 20.8%. Furthermore, our strategy can integrate filtering channels with existing multispectral systems, especially in which filtering wheels and multispectral filtering arrays setups, making it particularly suitable for weight-constrained, real-time applications like aerial surveillance or mobile sensing.</div></div>","PeriodicalId":18349,"journal":{"name":"Measurement","volume":"258 ","pages":"Article 119175"},"PeriodicalIF":5.6,"publicationDate":"2025-09-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145222802","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
MeasurementPub Date : 2025-09-28DOI: 10.1016/j.measurement.2025.119152
Zelong Li , Yifan Dai , Chaoliang Guan , Tao Lai , Hao Hu , Zizhou Sun , jianpeng wang
{"title":"High-precision sensitivity error analysis and compensation method for on-machine measurements of large aperture optical surfaces","authors":"Zelong Li , Yifan Dai , Chaoliang Guan , Tao Lai , Hao Hu , Zizhou Sun , jianpeng wang","doi":"10.1016/j.measurement.2025.119152","DOIUrl":"10.1016/j.measurement.2025.119152","url":null,"abstract":"<div><div>Large-aperture optical components are widely used in various fields. On-machine measurement systems can improve the measurement efficiency of optical surfaces during grinding. However, the measurement accuracy on the machine is limited by the accuracy of the machine tool and cannot meet the requirements. Currently, three-coordinate offline measurements are used for optical surfaces during grinding. However, offline measurements are inefficient. Therefore there is an immediate need for a high-precision on-machine measurement method. This study proposes a high-precision sensitivity error analysis and compensation method for on-machine measurements of large-aperture optical surfaces to replace coordinate measuring machine. The on-machine measurement precision of large-aperture optical surfaces was improved in two approaches. First, owing to the difficulty of directly compensating for all geometric errors of the machine tool, a sensitivity error model for surface measurements was established to identify the main sources of geometric errors. Second, an accurate error measurement and compensation method based on the Abbe principle was developed to ensure that no additional Abbe errors were introduced during the measurement process. Finally, the validity of the proposed method was verified using an on-machine measurement system to conduct precision tests on an aspheric surface with a diameter of 500 mm, and the results were compared with those obtained using a commercial profilometer. The measurement error was PV = 1.6 μm, RMS = 0.2 μm. Further on-machine measurements and machining experiments were performed on surfaces with the same diameter. The results show that the proposed method can effectively improve both the machining precision and efficiency, as demonstrated by the 50 % increase in the measurement efficiency compared to that achieved by coordinate measuring machine.</div></div>","PeriodicalId":18349,"journal":{"name":"Measurement","volume":"258 ","pages":"Article 119152"},"PeriodicalIF":5.6,"publicationDate":"2025-09-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145222803","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}